Apparatus and method for making and bagging decorative grass

ABSTRACT

An apparatus and method for producing and bagging decorative grass, comprising an extruder, a godet, a slitter, a cutter, a divider, a bagging assembly and a programmable logic controller. The extruder produces a continuous sheet of flexible material, which is fed by the godet into the slitter, cutter and divider. The slitter slits the sheet into a continuous web of strands of material. The cutter cuts the continuous web of strands, producing a quantity of decorative grass, which is then divided into discrete aggregates and sent by ducts to bagging assemblies, each of which has a rotatable turret having magazines for receiving and discharging discrete aggregates, an inserter and a bag handler. A programmable logic controller coordinates the production and bagging of the decorative grass, based on the properties of the sheet and the divider, and the predetermined properties of the decorative grass.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Ser. No. 09/962,547,APPARATUS AND METHOD FOR MAKING AND BAGGING DECORATIVE GRASS, filed Sep.25, 2001, the entire content of which is hereby incorporated herein byreference.

BACKGROUND OF INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to apparatus and methods for makingfilaments of decorative grass from sheet material and for uniformlydividing the filaments into a plurality of discrete aggregates ofdecorative grass for placement into bags or packages.

[0004] 2. Description of Related Art

[0005] U.S. Pat. No. 4,292,266, issued to Weder et al., discloses aprocess for making decorative grass. Plastic strips are passed through aslow godet, a drawing oven and a high speed godet to enable the stripsor strands to be drawn down in width and thickness without breaking.From the high speed godet, the strips or strands are chopped to adesired length and conveyed to a storage area.

[0006] The Weder '266 process does not segregate the decorative grassinto uniform charges for bagging and packaging. The decorative grass ismerely conveyed to a storage area.

[0007] U.S. Pat. No. 4,776,521, issued to Weder et al., discloses anapparatus and method for producing weighed charges of loosely aggregatedfilamentary material from compacted bales of the material. The apparatusincludes a rotating drum which disintegrates bales of filamentarymaterial into tufts of filaments. The tufts are passed to a pickingchamber, where a toothed roll strips individual filaments from a supplyroll formed from the tufts. The filaments are deposited on a scale untila charge of filaments is accumulated. Then air is blown across the scaleto discharge the scale.

[0008] The Weder '521 apparatus does not make decorative grass fromsheet material. Rather, the Weder '521 apparatus takes compacted balesof previously produced filamentary material, disintegrates the bales andweighs out charges of loose filaments.

[0009] U.S. Pat. No. 5,802,813, issued to Weder et al., discloses anapparatus and method for producing loose filaments from extruded sheetmaterial and for immediate packaging of the filaments in uniformquantities. The apparatus includes an extruder, a godet, a slitter, acutter and a bagging assembly.

[0010] The Weder '813 extruder provides a continuous length of sheetmaterial to the godet, which feeds the sheet material to the slitter.The slitter makes a number of longitudinal cuts in the sheet material todefine a plurality of continuous strips in the sheet of material. Thestrips are drawn into the cutter, where they are cut transversely toform individual filaments of decorative grass.

[0011] The individual filaments produced by Weder '813 are transferredto the bagging assembly. A programmable logic controller is provided tomonitor and control the speed of the godet, the cycles of the cutter andthe operation of the bagging assembly to separate the filaments intouniform charges of decorative grass.

[0012] Weder '813 does not provide for dividing the uniform charges ofdecorative grass into discrete aggregates of decorative grass forpackaging. Neither does it provide for slitting the sheet material in anon-longitudinal manner.

SUMMARY OF INVENTION

[0013] In one embodiment, the present invention is an apparatus andmethod for producing a decorative grass from extruded sheet material andfor immediate packaging of the decorative grass in predeterminedquantities. The apparatus includes an extruder, a godet, a slitter, acutter, a divider and at least one bagging assembly.

[0014] The extruder provides a continuous length of sheet material tothe godet, which feeds the sheet material to the slitter. The slittermakes a number of cuts in the sheet material to produce a web ofstrands. The web of strands is drawn into the cutter, where it is cut toproduce a quantity of decorative grass. This quantity of decorativegrass is then drawn into the divider, which apportions the filamentsinto discrete aggregates of decorative grass.

[0015] The discrete aggregates of decorative grass are transferred tothe bagging assemblies. A programmable logic controller is provided tomonitor and control the rate of extrusion, the speed of the godet, thecycles of the cutter and the operation of the bagging assemblies.

[0016] One object of the present invention is to provide an apparatuswhich produces decorative grass from sheet material and bagspredetermined quantities of the decorative grass in a continuousoperation.

[0017] Another object of the present invention is to provide anapparatus which requires no manual intervention from the extrusion ofthe sheet material through the bagging of the predetermined quantitiesof decorative grass.

[0018] Yet another object of the present invention is to increaseefficiency and profitability by increasing the width, and therefore theoverall quantity of grass continuously produced by a single machine,without sacrificing the accuracy of packaged material.

[0019] Still another object of the current invention is to moreaccurately package decorative grass by apportioning the grass intodiscrete aggregates in order to better manage the quantity of grass percharge.

[0020] Other objects, features and advantages of the present inventionare apparent from the following detailed description when read inconjunction with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF DRAWINGS

[0021]FIG. 1 is a schematic side elevational view of an apparatus formaking and bagging decorative grass in accordance with the presentinvention.

[0022]FIG. 2 is a schematic top view of a portion of the apparatus ofFIG. 1.

[0023]FIG. 3 is a flow diagram of set-up steps for a method of makingand bagging decorative grass in accordance with the present invention.

[0024]FIG. 4 is a flow diagram of production steps for a method ofmaking and bagging decorative grass in accordance with the presentinvention.

[0025]FIG. 5 is a partly diagrammatical top view of a bagging portion ofa preferred embodiment of the apparatus. In this particular embodiment,bags are formed from sheet material.

[0026]FIG. 6 is a partly diagrammatical side view of the bagging portionshown in FIG. 5.

[0027]FIG. 7 is a partly sectional, partly diagrammatical view of one ofthe bagging molds shown in FIGS. 5 and 6. A sheet of material is shownbefore being formed into a bag.

[0028]FIG. 8 is the same view as FIG. 7 except that the sheet ofmaterial is shown after being formed into a bag.

[0029]FIG. 9 is the same view as FIG. 8 except that the bag is filledwith decorative grass and is closed and sealed.

[0030]FIG. 10 is a partly sectional, partly diagrammatical view ofanother preferred embodiment of a bagging mold. This bagging mold formsa sheet of material into a bag shaped like an Easter bunny. The sheet ofmaterial is shown before being formed into a bag.

[0031]FIG. 11 is the same view as FIG. 10 except that the sheet ofmaterial is shown after being formed into a bag.

[0032]FIG. 12 is the same view as FIG. 11 except that the bag is filledwith Easter grass and is closed and sealed.

[0033]FIG. 13 is the same view as FIG. 12 except that the mold is opento release the filled bag of Easter grass.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Referring to the drawings in general, and to FIG. 1 inparticular, shown therein and designated by the general referencenumeral 10 is an apparatus for making and bagging decorative grass,which includes an extruder 12, a godet 14, a thickness gauge 16, aslitter 18, a cutter 20, a divider 21, a plurality of bagging assemblies22 and a programmable logic controller (PLC) 24.

[0035] The extruder 12 is any conventional machine which produces acontinuous sheet of flexible material from resins, colorants, additives,anti-static agents and flame retardants. A suitable extruder isdisclosed in U.S. Pat. No. 4,292,266 issued Sep. 29, 1981 to Weder etal., which is hereby incorporated by reference.

[0036] Similarly, the godet 14 may be any known device for feeding sheetmaterial from one location to another. A typical godet includes aplurality of rollers which are rotatable to dispense a continuous web ofsheet of flexible material 26. In the present invention, the godet 14receives the sheet of flexible material 26 from the extruder 12 andfeeds it into the slitter 18.

[0037] The thickness gauge 16 is typically located between the godet 14and the slitter 18 to measure the thickness of the sheet of flexiblematerial 26. A suitable thickness gauge 16 may be selected from severalinstruments which are available from Measurex, Inc. in Cupertino, Calif.As shown in FIGS. 1 and 2, the thickness gauge 16 is operativelyconnected to the PLC 24 to provide measurements of the thickness of thesheet of flexible material 26 to the PLC 24.

[0038] The slitter 18 includes a slitter surface 28, a plurality ofslitting devices 32 and a slitter hood 30. One of the slitting devices32 is designated by the reference numeral 32 and is generallyrepresentative of the slitting devices 32.

[0039] The slitting devices 32, which can be slitter blades in thepreferred embodiment, protrude from the slitter surface 28 with cuttingedges facing the incoming sheet of flexible material 26 to make aplurality of longitudinal cuts in the sheet of flexible material as thesheet of flexible material 26 travels through the slitter 18. It shouldbe appreciated that the slitting devices 32 are spaced across theslitter surface 28 at intervals to cut the sheet of flexible material 26into strips having the desired width for the decorative grass, therebyproducing a web of strands of material 37.

[0040] While the present embodiment uses slitter blades to induce aplurality of longitudinal cuts in the sheet of flexible material 26, itshould be understood that other methods for producing the web of strands37 can also suffice. For instance, a rolling or sliding blade couldinduce transverse cuts of predetermined width in the sheet of flexiblematerial 26 to produce the web of strands 37. Also, diagonal cuts couldbe made in the sheet of flexible material 26. Furthermore, non-linearstrands could be defined in the sheet of flexible material 26.

[0041] The slitter hood 30 extends angularly over the slitter surface 28to define a slitter entrance 34 and a slitter exit 36. The slitterentrance 34, slitter exit 36 and slitter hood 30 are sized and shaped toenhance an air flow for drawing the sheet material 26 into the slitterentrance 34 and the web of strands of material 37 out of the slitterexit 36. That is, the air space between the slitter hood 30 and thesheet of flexible material 26 gradually decreases from the slitterentrance 34 to the slitter exit 36. This construction accelerates theair flow through the slitter 18 from the slitter entrance 34 to theslitter exit 36 to keep the web of strands of material 37 substantiallystraight and moving smoothly through the slitter 18.

[0042] The cutter 20 includes a cutter housing 38 and a rotatable cutterblade 40. The cutter housing 38 communicates with the slitter exit 36 toreceive the web of strands of material 37 into the cutter housing 38.The cutter housing 38 has a cutter exit 42 for the discharge of aquantity of decorative grass 45.

[0043] Typically, the cutter blade 40 is attached to a cutter shaft 44,which is rotatably mounted within the cutter housing 38. A belt or chain46 and cutter motor 48 are operatively connected to the cutter shaft 44to rotate the cutter blade 40 as indicated by a rotational arrow 50.

[0044] It should be appreciated that the cutter blade 40 extends acrossthe width of the web of strands of material 37 to cut off the quantityof decorative grass 45 from the web of strands of material 37 with eachrevolution of the cutter blade 40. With a constant rate of travel of theweb of strands of material 37 and a constant rate of revolution for thecutter blade 40, the quantity of decorative grass is cut from the web ofstrands of material 37 in predetermined quantities.

[0045] A divider 21 communicates with the cutter exit 42 to receive thequantity of decorative grass 45 from the cutter exit 42. The divider 21includes an enclosed chute 47 having at least one and preferably aplurality of partitions 49. The partitions 49 of the divider 21cooperate with the cutter exit 42 to apportion the quantity ofdecorative grass 45 into discrete aggregates of decorative grass 53. Inone preferred embodiment, the partitions 49 are uniformly spaced apartso that the discrete aggregates of decorative grass 53 are formed withabout uniform weight and volume. However, it should be understood thatthe partitions 49 may be non-uniformly spaced apart.

[0046] A plurality of ducts 52 communicate with the divider 21 andextend to the bagging assemblies 22. Each adjacently disposed pair ofpartitions 49 defines a channel 55. Each duct 52 communicates with oneof the channels 55 to facilitate the transfer of a discrete aggregate ofdecorative grass 53 from the channel 55 to one of the bagging assemblies22. A plurality of blowers 54, one for each duct 52, is provided tocreate an air flow for transferring filaments of decorative grass out ofthe cutter housing 38, through the divider 21 and the ducts 52, to thebagging assemblies 22.

[0047] Since each duct 52 and blower 54 is identical to the other ductsand blowers, the same designation number is used on each of the ducts 52and blowers 54. Furthermore, the designation number used on the ducts 52and blowers 54 can refer to the ducts 52 and blowers 54 eitherindividually, or generally, as needed.

[0048] It should be appreciated that the cutter exit 42 is located at apoint lower than the cutter shaft 44 and the slitter exit 36. In thismanner, the quantities of decorative grass 45 cut from the slitted sheetmaterial 37 are drawn by the blowers 54 out of the cutter housing 38without being struck by the revolving cutter blade 40.

[0049] Furthermore, it should be understood that the number ofpartitions 49 is not limited to the number depicted in the drawings. Thedrawings are merely representational and should not be construed tolimit the number of partitions 49 for a particular divider 21.Conceivably, the number of partitions 49 is limited only by the numberof strands in the web of strands 37 generated by the slitter 18 and thecutter 20.

[0050] In fact, the divider need not contain partitions definingchannels. Other embodiments might divide the quantities of decorativegrass 45 into discrete aggregates of decorative grass 53 using a seriesof openings or a plurality of chutes down which each discrete aggregateof decorative grass 53 would fall. This process might be aided by ablower or a vacuum pump, thereby accelerating the process.

[0051] Additionally, using a blower or vacuum pump, the divider 21 couldseparate the quantities of decorative grass 45 into discrete aggregatesof decorative grass 53 utilizing a plurality of heads set over thequantities of decorative grass 45. A vacuum pump could draw the quantityof decorative grass 45 into the plurality of heads, thereby separatingit into discrete aggregates of decorative grass 53. The same effectcould be realized through the use of a blower, instead of a vacuum.

[0052] The alternative methods of dividing the decorative grass may beuseful for the separation of decorative grass with transverse ordiagonally disposed strands, since partitions may not separatequantities of decorative grass 45 with strands not cut longitudinally.

[0053] The bagging assemblies 22 each include a rotatable magazineturret 56, an index motor 58 for driving the rotation of the magazineturret 56, an inserter 60 and a bag handler 62. A suitable baggingassembly 22 is available from Prodo-Pak in Garfield, N.J.

[0054] Since each of the bagging assemblies 22 is identical to the otherbagging assemblies 22, all bagging assemblies 22 are referenced, eitherindividually or collectively, using the same designation number “22”.Also, since each of the bagging assemblies 22 is identical, only onebagging assembly 22 will be described in detail.

[0055] As best shown in FIG. 2, the magazine turret 56 has a pluralityof magazines extending from top 64 to bottom 66 through the magazineturret 56. One of the magazines is designated by reference numeral 68and is generally representative of the magazines of the magazine turret56.

[0056] Another one of the magazines, designated by reference character68 a, is in a fill position. Until rotated out of the fill position, themagazine 68 a communicates with the duct 52 to receive discreteaggregates of decorative grass.

[0057] Yet another one of the magazines, designated by referencecharacter 68 b, is in a discharge position. The magazine 68 b is locatedover a bag 70 for deposit of the filaments of decorative grass of themagazine 68 b into the bag 70.

[0058] A stationary plate 72 is located at the bottom 66 of the magazineturret 56 to cover the lower end of the magazines 68 which are waitingto be discharged into bags 70. Thus, the stationary plate 72 keeps thefilaments from falling out of the magazines 68 during filling, and afterfilling, until the discharge position is reached. Alternatively, thestationary plate 72 may be sized and shaped to cover the entire bottom66 of the magazine turret 56 except for the discharge position.

[0059] The index motor 58 is adapted to rotate the magazine turret 56 tolocate the magazines 68, one at a time, into the fill position. Themagazine turret 56 is rotated by the index motor 58 such that themagazines 68 advance from position to position in step-wise fashion.

[0060] As illustrated by FIG. 2, the magazine turret 56 typically haseight magazines 68. While one of the magazines 68 a is being filled withdecorative grass, another of the magazines 68 b is in the dischargeposition, three of the magazines are already filled and await rotationinto the discharge position, and three of the magazines are empty andawait rotation into the fill position. Although the magazine turret 56typically has eight magazines 68, it should be appreciated that themagazine turret 56 may have any number of magazines consistent with thescope and purpose of the present invention.

[0061] The inserter 60 comprises a pneumatic cylinder 74 having a piston76 which is extendable through the discharge magazines 68 b. A pushplate 78 is attached to the end of the piston 76 to force decorativegrass out of the discharge magazine 68 b and into the bag 70 as thepiston 76 is extended. Of course, the piston 76 and push plate 78 mustbe retractable from the discharge magazine 68 b in order for themagazine turret 56 to rotate when required.

[0062] It should be appreciated that a hydraulic or electric cylinder orany like device may be employed in place of the pneumatic cylinder 74.In an alternate embodiment, a blast of air, gases or gases containing ananti-static agent may be used to force the decorative grass from themagazines 68 instead of a cylinder and piston.

[0063] Furthermore, it should be understood that more than one duct 52may go to each turret 56. In fact, all the ducts 52 may go to a singleturret 56. Under such a system, the usage of the magazines 68 relativeto the ducts 52 could vary. For instance, the turret 56 could rotate themagazines 68 at each cut. Each magazine 68 would be indexed so that adifferent duct 52 would deposit its load at each cut, then indexedagain. In this way, the predetermined number of discrete aggregates ofdecorative grass 53 per charge of decorative grass would be equal to thenumber of ducts 52 per turret 56.

[0064] Alternatively, the number of ducts 52 could equal half the numberof magazines 68 in a turret 56. Under this method, the positions of theturret 56 would alternate between magazine 68 loading positions andmagazine 68 emptying positions, with the turret 56 being indexed after apredetermined number of cuts of the rotatable blade.

[0065] Many other possible combinations of ducts 52 and turrets 56 alongwith the methods of interaction between them are conceivable within thescope of the current invention. The embodiments listed above are to beconstrued as examples of the current invention.

[0066] The PLC 24 is operatively connected to the various components ofthe apparatus 10. In particular, the PLC 24 is connected to the extruder12 and the godet 14 to monitor and control the rate at which the sheetof flexible material 26 is fed to the slitter 18 and cutter 20. Further,the PLC 24 is programmed to receive as input the width, thickness anddensity of the sheet of flexible material 26 produced by the extruder12.

[0067] In addition, the PLC 24 is operatively connected to the cuttermotor 48 to monitor and control the speed of the cutter motor 48 and, inturn, the r.p.m.'s of the cutter blade 40. Further, the PLC 24 may beconnected to any conventional mechanical or electronic device 80 forsensing and counting the number of revolutions of the cutter blade 40.Such devices are well known in the art and any one of a number ofsuitable components may be used.

[0068] As shown in FIGS. 1 & 2, the PLC 24 may be operatively connectedto the air blowers 54, the index motors 58 and the inserters 60.Conventional devices and connections are provided to allow the PLC 24 tomonitor and control the air flow rates produced by the air blowers 54.The PLC 24 is connected to the index motors 58 to actuate the indexmotors 58 for rotating the magazine turrets 56 to advance theirrespective magazines 68.

[0069] The PLC 24 is connected to the inserters 60 to actuate theextension and retraction of the pistons 76 and push plates 78. Aplurality of upper limit switches 82, one for each piston, is providedand connected to the PLC 24 to indicate to the PLC 24 when therespective pistons 76 and push plates 78 are fully retracted from thedischarge magazines 68 b of the magazine turrets 56. Further, aplurality of lower limit switches 84, one for each piston, is providedand connected to the PLC 24 to indicate to the PLC 24 when therespective push plates 78 are fully extended through the dischargemagazines 68 b of the magazine turrets 56.

[0070] The bag handler 62 for each bagging assembly 22 is provided fordisposing an open bag beneath the discharge magazine 68 b. The baghandler 62 may comprise two bag racks 86 which are alternately rotatedunder the discharge magazine 68 b. In this manner, one bag rack 86supports a bag being filled with decorative grass while a filled bag isremoved from the other bag rack 86 and replaced with an empty bag. Itshould be appreciated that the bag handler 62 may be operated manuallyor may be a part of a conventional automated bag handling system (notshown).

[0071] Furthermore, it should be appreciated that the PLC 24 may controlthe respective bagging intervals between the indexing of the turrets 56by timing. Alternatively, the control of the bagging intervals may beeffected by referencing the indexing of the turrets 56 to apredetermined number of cuts of the cutter 20.

Operation

[0072] With reference to FIG. 3, shown therein are the steps executed bythe PLC 24 to set up the apparatus 10 for operation. First, the extruder12 is set to produce sheet material 26 having a known width and density.The sheet width and sheet density are input to the PLC 24. This may bedone manually or by any conventional connection between the extruder 12and the PLC 24.

[0073] As the sheet material 26 is advanced by the godet 14, thethickness gauge 16 measures the thickness of the sheet material 26. Thesheet thickness is automatically communicated from the thickness gauge16 to the PLC 24 (FIG. 3, Block 90). Thus, the sheet width, sheetdensity and sheet thickness are known quantities to the PLC 24.

[0074] Then, a length for the filaments comprising the decorative grassproduct is selected (Block 91). A travel speed for the sheet material 26and a rotational speed for the cutter blade 40 are selected to producefilaments of decorative grass having the selected filament length (Block92).

[0075] It should be appreciated that the width of the filaments isdetermined by the spacing of the slitting devices 32. It may bedesirable that the slitting devices 32 be removably mounted to theslitter surface 28. In this way, slitting devices 32 with differentspacings may be mounted to the slitter surface 28 in order to producefilaments in a wide variety of widths.

[0076] The production speed of the extruder 12, godet 14 and the airblower 54 are adjusted by the logic of the PLC 24 to achieve theselected travel speed (Block 93) of the sheet of flexible material 26through the slitter 18 and cutter 20. Further, the cutter motor 48 isset such that the cutter blade 40 has the rotational speed to producefilaments having the selected filament length for the selected travelspeed of the sheet of flexible material 26. Also, the number ofpartitions 49 of the divider 21 and/or the relative spacing of thepartitions 49 is selected (Block 94).

[0077] Utilizing the selected production speeds, sheet width, number orspacing of the partitions 49, sheet density, and sheet thicknessmeasured by the thickness gauge 16, the program logic of the PLC 24computes how many revolutions of the cutter blade 40 are required inorder to result in the desired uniform weight (Block 95) of grass to beplaced in each bag (Block 96). This computation of cutter blade 40revolutions is used by the PLC 24 to control the operation of thebagging assembly 22.

[0078] As illustrated by FIG. 4, the production and bagging ofdecorative grass is begun by zeroing the count of cutter blade 40revolutions and rotating an empty magazine 68 into the fill position(Block 100). Then the sheet of flexible material 26 is slit, cut,divided and blown into the magazines 68 a until the computed number ofrevolutions of the cutter blade 40 is reached (Block 101).

[0079] When the computed number of revolutions of the cutter blade 40 isreached, the PLC 24 causes the corresponding index motors 58 to rotatethe corresponding magazine turrets 56 such that the next magazine 68 ofthat magazine turrets 56 is situated in the fill position (Block 102).The count of cutter blade 40 revolutions is reset to zero. As soon asthe next magazine 68 is advanced into the fill position, it begins toreceive decorative grass from the duct 52.

[0080] Rotation of the corresponding magazine turrets 56 also movesfilled magazines 68 into the discharge position (Block 102). As soon asthe rotation of the magazine turret 56 is complete, the PLC 24 actuatesthe inserters 60 to force the contents of the discharge magazine 68 binto the bag 70 disposed below or adjacent to the discharge magazine 68b (Blocks 103 and 104).

[0081] Limit switches 82 and 84 for the respective magazine turrets 56sense when the push plates 78 of the inserters 60 are fully extendedthrough the discharge magazine 68 b and fully withdrawn from thedischarge magazines 68 b. The PLC 24 should also have logic to preventrotation of the magazine turrets 56 unless the push plates 78 arecompletely withdrawn from the discharge magazines 68 b.

[0082] After being filled, the bags 70 are moved from the dischargemagazines 68 b and respective empty bags are placed into position forreceiving grass during the next discharge cycle (Block 105). Typically,the filled bags are sealed, labeled and packaged for shipment to pointsof distribution and sale.

[0083] As soon as each discharge cycle is initiated, the PLC 24 zeroesthe counter for the revolutions of the cutter blade 40 and thefill-and-discharge procedure is repeated. By utilizing the calculationsof the PLC 24 and the counter device 80, scales for weighing out uniformquantities of decorative grass are eliminated.

[0084] By obviating the need for scales, the present inventionsimplifies the task of uniformly bagging decorative grass. Further, thepresent invention allows the production and bagging of decorative grassin a single, continuous operation.

[0085] The present invention may be modified in a wide variety of ways.For example, the thickness of the sheet of flexible material 26 from theextruder 12 may be assumed to be substantially constant. In such a case,the thickness gauge 16 may be replaced by any known device for measuringthe length of sheet material passing by the device. The PLC 24 maycontrol the components of the system according to the lengths measuredby the device rather than by the density and travel speed of the sheetof flexible material 26 and the revolutions of the cutter blade 40.

[0086] As another example, the thickness and travel speed of the sheetof flexible material 26 may be assumed to be substantially constant. Inthis instance, any conventional timing device may be used in place ofthe thickness gauge 16 and the revolution counter device 80. The PLC 24may control the components of the system according to time intervalscorresponding to the density, dimensions and travel speed of the sheetof flexible material 26.

Bag Formation

[0087] With reference to FIG. 5 through 9, shown therein and designatedby reference character 90 is a preferred embodiment of a bagging systemwhich forms bags from sheet material. The bagging system 90 comprises amold turret 92, an a.c. power source 94, a vacuum source 96, a motor 98,a heat source 100, a roll of sheet material 102 and a sheet cutter 104.As shown in FIG. 5, the PLC 24 is connected to the bagging system 90 tocontrol and coordinate its functions according to the sequence ofoperations disclosed herein below.

[0088] The mold turret 92 includes a plurality of bagging molds 106 andis rotatable by the motor 98. Further, the mold turret 92 is arrangedsuch that the bagging molds 106 are successively positioned at thedischarge end of the discharge magazine 68 b position as the mold turret92 is rotated.

[0089] As shown in FIG. 6, a blower 108 may be provided to urge thedecorative grass from the discharge magazine 68 b into a receiving bag110. However, the bagging system 90 may have the inserter 60 instead ofthe blower 108 (FIG. 1) for urging the grass into the bag 110.

[0090] A pair of rollers 112 are provided to support the roll 102 ofsheet material over a substantially flat feed surface 114. The rollers112 are adapted to successively feed end portions 116 of the sheetmaterial to a position over an empty bag mold 106 e.

[0091] A pair of feed rollers 117 are rotatably mounted to feed sheetmaterial there between along the sheet feed surface 114. The sheetcutter 104 is mounted over the sheet material for successively cuttingend portions 116 from the continuous length of sheet material.

[0092] With reference to FIG. 7 through 9, shown therein is one of thebagging molds 106 in detail. Typically, each bagging mold 106 isgenerally cylindrical. However, it should be appreciated that thebagging molds 106 may be constructed in a wide variety of shapes.

[0093] Each bagging mold 106 has a first end 118, a second end 120 and amold opening 122 extending from the first end 118 toward the second end120. Around the first end 118, a substantially flat holding surface 124is provided to support a sheet 126 cut from the end portion 116 of theroll 102 of sheet material.

[0094] The holding surface 124 has a plurality of vacuum holes 128 formaintaining the cut sheet 126 in place by means of a vacuum. Further, alower portion of the side walls and all of the bottom walls of eachbagging mold 106 have an inner wall 130 and an outer wall 132. The innerwalls 130 and outer walls 132 are spaced apart to define a vacuumannulus 134.

[0095] The inner wall 130 is provided with a plurality of inner vacuumholes which communicate with the mold opening 122 and the vacuum annulus134. Several of the inner vacuum holes are designated by referencenumeral 136 and are generally representative of the interior vacuumholes.

[0096] Vacuum lines 138 are provided to connect the vacuum holes 128 and136 to the vacuum source 96. A vacuum valve 140 is located in eachvacuum line 138 to control the amount of vacuum applied to the vacuumholes 128 and 136.

[0097] In operation, the end portion 116 of the sheet material 102 isfed over the empty bagging mold 106 e. Vacuum is applied to the vacuumholes 128 in the holding surface 124 of the empty bagging mold 106 e.Then the sheet cutter 104 is actuated to cut the end portion 116 fromthe sheet material 102 (FIG. 6 and 7).

[0098] The vacuum on the vacuum holes 128 in the holding surface 124 isreduced or cut off as the vacuum on the inner vacuum holes 136 isincreased or turned on. This action draws the end portion 116, which isnow a cut sheet 126 of material into the mold opening 122 of the baggingmold 106 e to form the bag 110 (FIG. 8).

[0099] The cutting and bag forming may be performed at the samerotational position of the mold turret 92. Alternatively, the cuttingmay be done at one position and the bag forming may take place at anyother rotational position before the bag filling position.

[0100] The mold turret 92 is rotated to place the formed, empty bag 110in the bag filling position. The blower 108 produces an air flow toforce the decorative grass from the magazine of the magazine turret 56and into the bag 110 in bagging mold 106 f (FIGS. 6 and 9).

[0101] The filled bag 110 may then be closed and sealed in anyconventional manner, such as with a twist tie, closure tag, adhesivestrip or the like. As shown in FIG. 9, a plurality of closure blocks 146moveable by closure cylinders 148 may be provided to close the filledbag 110

[0102] Alternatively, the sheet of material may comprise anyconventional adhesive or cohesive substance to seal the bag closed uponcontact with itself. In another preferred embodiment, the sheet materialmay comprise any conventional heat-sealable substance and the heatsource 100 may be connected to each closure block 146 to effectheat-sealed closure of each bag 110 (FIG. 9).

Embodiment of FIG. 10 through 13

[0103] Referring to FIG. 10 through 13, shown therein and designated byreference numeral 150 is a preferred embodiment of a bunny mold. Thebunny mold 150 is constructed to form the cut sheet 126 of material intoa bag in the shape of an Easter bunny.

[0104] The bunny mold 150 is a split mold having two ear halves 152 andtwo body halves 154. An ear cylinder 156 is connected to each ear half152 to move the ear halves 152 between an open and a closed position.Similarly, a body cylinder 158 is attached to each body half 154 to movethe body halves 154 between an open and a closed position.

[0105] Each one of the ear halves 152 and the body halves 154 have innerwalls 160 and outer walls 162 separated by a vacuum annulus 164. Theinner walls have a plurality of vacuum holes 166 communicating with thevacuum annulus 164. Vacuum lines 168 and vacuum valves 170 are providedto connect the vacuum annulus 164 of each ear half 152 and each bodyhalf 154 to the vacuum source 96.

[0106] A substantially flat holding surface 172 with a plurality ofvacuum holes 174 is provided above the ear halves 152 to support the cutsheet 126 of material. The holding surface 172 has an opening 176 therethrough to allow the cut sheet 126 of material to be drawn by vacuuminto the interior of the bunny mold 150.

[0107] In operation, the ear halves 152 are moved to the open positionand the body halves 154 are moved to the closed position. At this time,the cut sheet 126 of material is held by vacuum through the vacuum holes166 of the holding surface 172 (FIG. 10). For clarity of illustration,the vacuum source 96, the vacuum valves 170 and portions of the vacuumlines 168 are not shown in FIG. 10-13.

[0108] Next, the vacuum on the vacuum holes 174 in the holding surface172 is reduced or cut off as the vacuum on the inner vacuum holes 166 isincreased or turned on. This action draws the cut sheet 126 of materialthrough the opening 176 of the holding surface 172 and into the bunnymold 150 (FIG. 11). For clarity of illustration, the heat source 100,the vacuum source 96, the vacuum valves 170 and portions of the vacuumlines are not shown in FIG. 11 through 13. It should be appreciated thatthe cut sheet 126 of material should be sufficiently flexible to bedrawn against the inner walls 160 within the bunny mold 150 by thevacuum.

[0109] After the bag is filled with decorative grass, the ear halves 152are closed to form the ears and to seal the bag (FIG. 12). The cut sheet126 of material may comprise any conventional adhesive or cohesivesubstance, in which case the bag seals shut upon contact with itself.

[0110] In another preferred embodiment, the cut sheet 126 of materialcomprises a heat-sealable substance. In this case, heat is applied byheat sources 100 to an upper portion of each one of the ear halves 152to effect a heat-sealed closure of the bag (FIG. 10 and 12).

[0111] Once the bag is sealed, both the ear halves 152 and the bodyhalves 154 are opened to release the formed, filled and sealed bag (FIG.13).

[0112] It should be appreciated that a wide variety of molds may beutilized in a manner similar to that disclosed herein. For example,molds for forming bags in the shape of chicks, ducks, any other animalsor any inanimate object may be constructed within the scope and purposeof the present invention.

Low-Density Decorative Grass

[0113] Referring back to FIG. 1, the foam injector 25 is connected tothe extruder 12 to inject a foaming agent or blowing agent into thematerial being extruded into sheet material. The foaming agent isprovided to produce a sheet of flexible material 26 having a lowdensity.

[0114] The foaming agent may be air, nitrogen or any suitable gaseousmixture or compound. In this case, the foaming agent is injected intothe extrusion mixture under pressure to create tiny gas bubbles in theextruded material.

[0115] In another preferred embodiment, the foaming agent is a compoundor substance which is activated by heat to evolve a gas such as carbondioxide. Examples of this type of foaming agent are baking powder,sodium bicarbonate, ammonium carbonate, pentane and hydrazine andrelated compounds.

[0116] In using one of the heat-activated foaming agents, pellets forthe extrusion material, such as polystyrene pellets, and the foamingagent are introduced into the extruder 12. Heat is used to melt thepellets and with the heat the foaming agent evolves a gas into thematerial to reduce the density of the extruded material.

[0117] Changes may be made in the combinations, operations andarrangements of the various parts and elements described herein withoutdeparting from the spirit and scope of the invention as defined in thefollowing claims.

What is claimed is:
 1. An apparatus for continuously producing anddividing decorative grass from a web of strands of material havingpredetermined widths, the apparatus comprising: a cutter adapted toreceive the web of strands of material having predetermined widths, thecutter cutting the web of strands at a constant rate, to produce aplurality of quantities of decorative grass having a predeterminedlength; and means for dividing each quantity of decorative grass intodiscrete aggregates of decorative grass.
 2. The apparatus of claim 1,further comprising a programmable logic controller monitoring andregulating the rate at which the cutter cuts the web of strands ofmaterial to produce each quantity of decorative grass.
 3. The apparatusof claim 1, further comprising a programmable logic controllermonitoring and regulating the rate at which the quantities of decorativegrass are produced.
 4. An apparatus for continuously producing anddividing decorative grass from a web of strands of material having apredetermined width, the apparatus comprising: means for producing acontinuous sheet of flexible material having a thickness, a width, adensity and a predetermined travel speed; means for slitting thecontinuous sheet of material to produce the web of strands of materialhaving predetermined widths; a cutter adapted to receive the web ofstrands of material having predetermined widths, the cutter cutting theweb of strands at a constant rate, to produce a plurality of quantitiesof decorative grass having a predetermined length; and means fordividing the qualities of decorative grass into discrete aggregates ofdecorative grass.
 5. The apparatus of claim 4, wherein the cutterfurther comprises: a rotatable blade; and means for rotating therotatable blade at a predetermined rotational rate corresponding to thetravel speed of the continuous sheet of material so that quantities ofdecorative grass are produced having a predetermined length.
 6. Theapparatus of claim 5, wherein the apparatus further comprises: means fordetermining the predetermined travel speed of the continuous sheet ofmaterial and the predetermined rotational rate of the rotatable blade;and means for adjusting the travel speed of the continuous sheet ofmaterial and the rotational rate of the rotatable blade to producequantities of decorative grass at the predetermined rate.
 7. Theapparatus of claim 1, wherein the cutter includes a cutter housinghaving a cutter exit for the discharge of the strands of decorativegrass.
 8. The apparatus of claim 7, wherein the means for dividing thestrands of decorative grass includes at least one partition defining aplurality of channels, at least one partition cooperating with thecutter exit to apportion each quantity of decorative grass into discreteaggregates of decorative grass.
 9. The apparatus of claim 8, wherein theapparatus further comprises: a plurality of bagging assemblies, eachbagging assembly capable of accumulating a predetermined number ofdiscrete aggregates of decorative grass to form a charge of decorativegrass and disposing the charge of decorative grass into a bag; and aplurality of duct assemblies communicating with the channels and thebagging assemblies for transporting the discrete aggregates ofdecorative grass from the channels to the bagging assemblies.
 10. Theapparatus of claim 9, wherein each duct assembly includes a ductextending from one of the channels to one of the bagging assemblies, anda blower for producing an air flow within the duct.
 11. The apparatus ofclaim 9, further comprising a bag handler for positioning the bag toreceive the charge of decorative grass.
 12. The apparatus of claim 11,wherein the bag handler is movable at a bagging interval between a fillposition and a discharge position.
 13. The apparatus of claim 12,further comprising a programmable logic controller regulating thebagging interval of the bag handler based on the number of cuts made bythe cutter.
 14. The apparatus of claim 12, further comprising aprogrammable logic controller regulating the bagging interval of the baghandler based on an elapsed interval of time.
 15. The apparatus of claim9, wherein each of the bagging assemblies includes a plurality ofmagazines movable at a bagging interval between a fill position and adischarge position whereby discrete aggregates of decorative grass areaccumulated in the magazines in the fill position to form the charges ofdecorative grass, the charges of decorative grass being discharged intoa bag in the discharge position.
 16. The apparatus of claim 15, whereineach bagging assembly includes an inserter positioned for dischargingthe charges of decorative grass into the bag.
 17. The apparatus of claim16, wherein the inserter comprises a pneumatic cylinder having a pistonwhich is extendable through the magazine positioned in the dischargeposition.
 18. The apparatus of claim 15, further comprising aprogrammable logic controller outputting signals to cause the magazinesto move between the fill position and the discharge position.
 19. Theapparatus of claim 18, wherein the programmable logic controllerregulates the bagging interval based on the number of cuts made by thecutter.
 20. The apparatus of claim 18, wherein the programmable logiccontroller regulates the bagging interval based on an elapsed intervalof time.
 21. A method for making decorative grass from a continuoussheet of material, the method comprising the steps of: slitting acontinuous sheet of material to produce a web of strands of material;cutting across the web of strands of material at a cutting rate toproduce a quantity of decorative grass having a predetermined length;and dividing the quantity of decorative grass into a plurality ofdiscrete aggregates of decorative grass.
 22. A method for makingdecorative grass from continuous sheet material, the method comprisingthe steps of: providing a continuous sheet of material having a sheetwidth, a sheet thickness and a sheet density; selecting a predeterminedlength and width for decorative grass, and at least one predeterminedweight for charges of decorative grass to be bagged; selecting thenumber of discrete aggregates of decorative grass produced per cut andthe weight of each discrete aggregate of decorative grass such that thesum of the weight of one or more discrete aggregates of decorative grasssubstantially totals the predetermined weight of a charge of decorativegrass; slitting the continuous sheet material to produce a web ofstrands of material; cutting across the web of strands of material at aconstant rate corresponding to the predetermined length of thedecorative grass to make a quantity of decorative grass; and dividing,at each cut, the quantity of decorative grass into the predeterminednumber of discrete aggregates of decorative grass per cut.
 23. A methodfor making and bagging decorative grass from continuous sheet material,the method comprising the steps of: providing a continuous sheet ofmaterial having a sheet width and a sheet density; measuring thethickness of the sheet material; selecting a length and width for adecorative grass, and at least one predetermined weight for charges ofdecorative grass to be bagged; selecting the number of discreteaggregates of decorative grass produced per cut and the weight of eachdiscrete aggregate such that the sum of the weight of one or morediscrete aggregates of decorative grass totals the predetermined weightof a charge of decorative grass; slitting the continuous sheet ofmaterial to produce a web of strands of material; cutting across the webof strands of material at a constant rate corresponding to thepredetermined length of the decorative grass to make a quantity ofdecorative grass; dividing the quantity of decorative grass into thepredetermined number of discrete aggregates of decorative grass; andbagging the discrete aggregates of decorative grass so that thepredetermined weights of charges of decorative grass are bagged.
 24. Themethod of claim 23 wherein the step of providing a continuous sheet ofmaterial further comprises the steps of: providing an extruder; andinjecting a foaming agent into the extruder to lessen the density of thecontinuous sheet of material produced by the extruder.
 25. The method ofclaim 23 wherein the step of providing a continuous sheet of materialfurther comprises the steps of: providing an extruder; and introducingan extrusion material containing a foaming agent into the extruder. 26.A method for continuously producing and bagging decorative grass, themethod comprising the steps of: a. producing at a predetermined rate aquantity of decorative grass comprising elongate and flexible filamentsof material; b. dividing at a predetermined rate the quantity ofdecorative grass into a plurality of discrete aggregates of decorativegrass using a divider having at least one partition; c. positioning abag to receive at least one discrete aggregate of decorative grass; d.transferring at least one discrete aggregate of decorative grass intothe bag based on the predetermined rate at which the decorative grass isbeing produced and on the number of partitions in the divider; e.removing the bag containing the decorative grass; and f. repeating stepsc, d, e, and f.
 27. The method of claim 26 further comprising the stepsof: providing a continuous sheet of material having a thickness, awidth, a density and a predetermined travel speed; slitting thecontinuous sheet of material to produce a web of strands of materialhaving a predetermined width; and cutting the continuous strands ofmaterial into quantities of decorative grass.
 28. The method of claim 27further comprising the steps of: providing a rotatable blade; androtating the rotatable blade at a predetermined rotational ratecorresponding to the travel speed of the continuous sheet of material sothat quantities of decorative grass are produced having a predeterminedlength.
 29. The method of claim 28 further comprising the steps of:determining the predetermined travel speed of the continuous sheet ofmaterial and the predetermined rotational rate of the rotatable blade;and adjusting the travel speed of the continuous sheet of material andthe rotational rate of the rotatable blade to produce quantities ofdecorative grass at the predetermined rate.
 30. An apparatus forcontinuously producing and bagging decorative grass, the apparatuscomprising: means for producing a continuous flexible sheet of materialhaving a thickness, a width, a density and a predetermined travel speed;means for slitting the continuous flexible sheet of material to producea web of strands of material having a predetermined width; a rotatableblade positioned to cut the web of strands of material to produce aquantity of decorative grass comprising elongate, flexible filaments;means for rotating the rotatable blade at a predetermined rotationalrate corresponding to the travel speed of the continuous flexible sheetof material so that the quantity of decorative grass is produced havinga predetermined length and is produced continuously at a predeterminedrate; means for dividing at a predetermined rate the quantity ofdecorative grass into a plurality of discrete aggregates of decorativegrass, said means having at least one partition; means for positioning afirst bag to receive at least one discrete aggregate of decorativegrass; means for transferring at least one discrete aggregate ofdecorative grass into the first bag, the weight and volume of thediscrete aggregate of decorative grass being based on a predeterminednumber of revolutions of the rotatable blade and on the number ofpartitions in the aforementioned means for dividing the quantity ofdecorative grass; and means for removing the first bag containing thediscrete aggregates of decorative grass and for positioning a second bagto receive discrete aggregates of decorative grass.
 31. The apparatus ofclaim 30 wherein the apparatus further comprises: means for determiningthe predetermined travel speed of the continuous sheet of material andthe predetermined rotational rate of the rotatable blade; and means foradjusting the travel speed of the continuous sheet of material and therotational rate of the rotatable blade to produce strands of decorativegrass at the predetermined rate.
 32. A method for continuously producingand bagging filaments of material, the method comprising: a. providing acontinuous sheet of flexible material having a thickness, a width, adensity and a predetermined travel speed; b. slitting the continuoussheet of flexible material to produce a web of strands of materialhaving a predetermined width; c. rotating a rotatable blade at apredetermined rotational rate corresponding to the travel speed of theweb of continuous strands of material so that a quantity of decorativegrass is cut from the web of continuous strands of material having apredetermined length and is produced continuously at a predeterminedrate; d. dividing at a continuous and predetermined rate the quantity ofdecorative grass into a plurality of discrete aggregates of decorativegrass using a divider having at least one partition; e. positioning abag to receive at least one discrete aggregate of decorative grass; f.transferring at least one discrete aggregate of decorative grass intothe bag, the weight and volume of the discrete aggregate of decorativegrass being based on a predetermined number of revolutions of therotatable blade and on the number of partitions in the divider; g.removing the bag containing the discrete aggregates of decorative grass;and h. repeating steps c, d, e, f, g, and h.
 33. The method of claim 32further comprising the steps of: determining the predetermined travelspeed of the continuous sheet of material and the predeterminedrotational rate of the rotatable blade; and adjusting the travel speedof the continuous sheet of material and the rotational rate of therotatable blade to produce strands of decorative grass at apredetermined rate.
 34. A method for continuously producing and baggingdecorative grass, the method comprising the steps of: a. extrudingcontinuous strands of flexible material with each strand having apredetermined thickness, width, density and travel speed; b. cutting ata continuous and predetermined rate the continuous strands of flexiblematerial into a quantity of decorative grass comprised of elongatefilaments of material; c. dividing the quantity of decorative grass intoa plurality of discrete aggregates of decorative grass using a dividerhaving at least one partition; d. positioning a bag to receive at leastone discrete aggregate of decorative grass; e. transferring at least onediscrete aggregate of decorative grass into the bag based on thepredetermined rate at which the decorative grass is being produced andon the number of partitions in the divider; f. removing the bagcontaining the decorative grass; and g. repeating steps b, c, d, e, f,and g.
 35. The method of claim 34 further comprising the steps of:providing a rotatable blade; and rotating the rotatable blade at apredetermined rotational rate corresponding to the travel speed of thecontinuous sheet of material so that quantities of decorative grass areproduced having a predetermined length.
 36. The method of claim 35further comprising the steps of: determining the predetermined travelspeed of the web of strands of material and the predetermined rotationalrate of the rotatable blade; and adjusting the travel speed of the webof strands of material and the rotational rate of the rotatable blade toproduce quantities of decorative grass at the predetermined rate.